Machine for and method of winding folded webs



ocnzs, 1932." N MARCALUS 1,884,783

MACHINE FOR AN METHOD OF WINDING FOLDED WEBS Filed Aug. 19. 193C '5 Sheets-Sheet l ,8W ATTORNEYS Oct. 25, 1932. N, MARCALUS l 1,884,783

A MACHINE FOR AND METHOD F WINDINGQ FOLDED wEBs 4W ATTORNEY:

Oct. 25, 1932. N. MARcALUs 1,884,783

MACHINE FOR AND METHOD OF WINDING FOLDED WEBS Filed Aug. 19, 1930 5 Sheets-Sheet 5 AQ ATTORNEYS Oct. 25, 1932. N. MARcALUs MACHINE FOR AND METHOD OF WINDING FOLDED WEBS Filed Aug. 19, 195C 5 Sheets-Sheet 4 INV NTOR Oct. 25, 1932. N, MARCALUS 1,884,783

MACHINE FOR AND METHOD 0F WINDING FOLDED wEBs Filed Aug. 19, 1950 5 Sheets-Sheet 5 @ATTORNEYS Patented Oct. Z5, 1932 Midifiles@ S'EATES earsnr OFFICE NICHOLAS N-ARCELUS, OF ELIZABETH, NEW JERSEY, ASSIGNOB TO AUTOMATIC PAPER MACHINERY CO. INC., A CORPORATIGN OF NEW JERSEY MACHINE FR, AND METIOD 0F WINDING FOLDED WEBS Application filed August 19, 1930. Serial` No. 476,428.

This invention relates to machines for and method of winding folded webs.

It is common commercial practice to retail paper wound upon cardboard cores, for example waxed paper used for wrapping foods. For convenience in merchandising, as well as in using, these rolls are usually made about twelve inches long so that the width of the wound strip is only twelve inches. For many uses a wider strip is desirable; for example, tissue paper used for wrapping gifts at Christmas time is always more than twelve inches wide. In order to get a wider wound strip either a, longer core and longer package must be used or the strip must be folded before winding. t would be simple enough to wind a wider strip, but a roll, substantially longer, say twenty-four inches long would be awkward to handle both for the merchant and for the user. The alternative, to wind a folded web, presents difficulties. rllhe inner ply invariably buckles and when unwound is found to be badly wrinkled. Such a product is unattractive and `is not commercially desirable. Another diflicultyinherent in the winding of folded webs is this: The thickness at the fold is always more than twice the thickness of the single ply unless the foldbe so sharp as to rupture the fibers-thus as the winding proceeds the diameter of the roll at the fold increases faster than elsewhere, complicating the winding and producing a misshapen wrinkled roll. It is, therefore, my object to produce a tightly wound roll of folded material free from wrinkles and of uniform diameter. The paper roll constituting the product of the machine and method described in the present application forms 'the subject in aticr of my ccp-ending divisional application Serial No. 543,063, filed June 9, 1931.

New the reason the inner ply of a folded web buckles and wrinkles when wound is that in wir. ding, the outer ply must travel farther than the inner, being wound in effect upon a core larger, by the thickness of the web itself, than the core upon which the inner ply being wound. and yet both plies are of the same length and` being of one piece must travel together without relative slippage.

Thuseither the outer ply must. tear or the i inner ply must Wrinkle. Because of the tensile strength of the paper the inner ply usually wrinkles. In accordance with the present invention I elongate the outer ply relative to the inner before winding just enough to compensate for the dilference in winding length between the two plies. This relative elongation may be effected by stretching the outer ply, causing an actual shift in. the fibers themselves, or by crimping the web transversely so that a differential elongation of the two plies is automatically effected during winding. In order to wind a smooth roll of uniform diameter despite the increased thickness of the material at the fold, I cause the core to traverselongitudinally during the winding so that the folded edge does not wind upon itself, each convolution being slightly displaced axially with reference to its predecessor.

In the accompanying drawings I have illustrated certain preferred embodiments of my invention. In these drawings Figure 1 is a side elevation of a web Winding machine constructed in accordance with the present invention; Figure 2 is a front elevation of the same machine; Figure 3 is a horizontal section taken along line 3-3 of Figure 1; Fig ure 1- is an enlarged vertical section through the winding rollers and associatedy mechanism taken along line 4-4 of Figure 2; Figure 5 is a detail of the former over which the paper is folded; Figure 6 is a side view of the former; Figure 7 is a horizontal section taken along line 77 of Figure 5; FigureV 8 is a detail partly in section taken along line 88 of Figure 2; Figure 9 is a side elevation of the completed roll; Figure 10 is a horizontal section through the roll; Figure 11 is` an enlarged detail showing the structure of the web at the fold; Figure 12 is a diagrammatic illustration of a folded we J-wound in accordance with the present invention; Figure 13 is a similar view showing the buckling of the inner ply on a folded web wound under ordinary conditions; Figure 14: illustrates the condition of the web of Figure 15 when unrolled and opened out flat; Figure 15 is detail showing means employed for than throughout the body of the roll.

decreasing the elongation ratio as the diameter of the wound roll increases; Figure 16 is a diagrammatic view showing the crimping rollers, and Figure 17 is a detail, very much enlarged and exaggerated show ing the relation between inner and outer crimped plies on a wound roll.

I shall first refer to Figures 12 and 13 and describe in some detail just whathappens when a folded web is wound. In these ligures, 2O represents a web folded at 21 to formv an inner ply 22 and outer ply 23.l

Let R=the radius of curvature of the inner ply at any given point, T=the thickness of the web, and 'S=the space between the two plies.

Although for any given convolution the cross section of each lply is spiral rather than truly circular, the error involved in considering the form asfcircular is small and can be disregarded. For any given convolution, therefore:

Length of outer ply=21r(R+T-| S) Length of inner ply=21rR Difference in length=21r T+S It is clear, therefore, that for every convolution the length ofthe outer ply must exceed 'the length of the inner ply by 6.28 times the thickness of the web plus Vthe space between the two plies-a constant for any given paper and tightness of'winding.

As a result of this disparity, a loosely wound folded web will assume roughly the form illustrated in Figure 13 with the inner ply buckling at points 24. When the roll is tightly wound, as it must be in commercial practice, these bulges -24 are flattened out and form creases or wrinkles 25 which remain as s uch in the paper when it is unwound and attened, as'illustrated in Figure 14. I avoid this by stretching the outer ply before vwinding an amount substantially equal to the difference in length.

Referring now to Figure 11 it will be noted that where the paper is folded at 21, a loop is formed having a greater thickness than twice the thickness of the plies, To make a sharper fold would rupture the fibres and weaken the paper along the fold when it is unfolded for use. If a folded web is wound in the ordinary fashion, the diameter ofthe roll, at the fold, will increase more rapidly In order to avoid this, I wind the folded web helically, as illustrated in Figures 9 and 10 in which 26 indicates the lcardboard core on which the web is wound.,` As illustrated in these views the web is displaced relative to the core as the winding proceeds so-that successive convolutions of the fold do not overlap. The paper roll as above described forms the subject of my co-pending divisional application Serial No. 543,063. i

The machine which I have invented unwinds a wide web from a parent roll, folds it once to make a two-ply strip and winds the folded strip upon a cardboard core. Simultaneously with the folding operation onehalf of the web, that half which will constitute the outer ply during the winding, is elongated slightly to compensate for its longer path of travel during winding. As the winding proceeds the core is caused to traverse longitudinally to wind the folded web helically and thus prevent overlapping of the thickened portion at the fold. I shall now describe this machine with particular reference tothe drawings.

The machine generally comprises a frame 30 mounted upon a base 31. On one side of the basefa parent or jumbo roll 32, is mounted on a shaft 33 rotatably supported upon standards 34. A brake drum 35 is mounted upon one end of the shaft 33 and over this brake drum extends a brake band 36 fixed, at one end, to one of the standards 34 and connected at the other end to a pivoted lever 37, the position of which can be adjusted by means of handwheel 38 to vary the braking pressure exerted by the band and thus vary the tension of the web as it is unwound from the parent roll. The web as it is unwound from the parent roll passes up-V ward between two feed rollers 40 and 41 mounted at the upper end of the frame and then downward over a triangular folding former 42 which folds the web upon itself once. The folded web then passes down-y ward through feed rollers 43 and 44 to the core 26 which is held by three winding rollers 45, 46 and 47. These winding rollers wind the folded web upon the core by surface contact. IVinding roller 47 is swingingly mounted to Inoveoutward as the diameter of the wound roll increases. When the desired length of material has been wound, the roller 47 is swung free of the roll which is then severed from the web and removed from thev machine.

rlhe folding former 42 is provided along its paper-contacting edges with bars 49 and 50 over which the web passes during the folding operation. In order to stretch half of the web, that half which is to form the outer ply during winding, I provide means for adjusting the bar 49 so that it may be raised above the bar 50 and thus increase the path which that half of the web passing it must travel, thus causing a slight elongation of lthat half of the web. This adjustment of the bar 49 is 'effected by means of a series of set screws 51, as illustrated in Figure G.

In order to facilitate the stretching operation I have provided means for dampening that half of the web which is to be elongated. This means comprises a steam pipe 52 mounted just above the folding former and pro` vided with a slot 53 through which steam passes into-.a chamber 54 defined by side walls 55 secured to and extending from: the steam pipe, andA closed by the web itself. That section of the web lying between the side walls 55 is dampened by Contact with the steam and water vapor issuing from the pipe and thus better conditioned for stretching. The amount of steaml employed can be regulated by means of a hand-operated valve 56. Girly that half of the web which is to be stretched is subjected to this dampening treatment.

l shall now describe the mechanism by which the rolls are driven, referring particularly tov Figures l, Q and The machine is drivenA by means of a pulley mounted on a `shaft 6l and receiving its power from any desired source. Bevel gear G2 keyed on shaft 6l drives bevel gear 63 mounted on shaft 6l of winding roller d5. Likewise keyed on shaft 64 is spur gear 65 which meshes with idler gear 66 which in turn meshes with gear 67 on the shaft of feeding roller d3 and also with gear 68 on the shaft of winding roller 46. llleshing with gear 67 is 69 mounted on the shaft of feeding roller all. Extending beyond the gear G9 and fixed thereto (see Fig. l) is a bevel gear 70 meshing with bevel gear 7l on a shaft 73, which extends upwardiy at an angle terminatin in bevel gear 7-i meshing with bevel gear 7 5` on the shaft of feeding roller 451. Feeding roller l0 is held in contact with roller Lil under the pressure of springs 76 and rotates with the roller il, but is not positively driven.. Spur gear 65 also meshes with a large idler gear 7 7 journaled on bushing 78, and gear 77 meshes with gear 80` keyed to the shaft 8l of the swinging winding roller 47. This shaft 8l is journalled in the upper ends of ceunterweighted ar ns 82 and 83, each of which keyed to a tube Si passing through and ournalled wi hin the bushing 73 and also within a corresponding bearing 35 on the other side of the frame. As the winding roll increases in size the winding roller i7 swings outwardly, the gear SO'continuin to mesh with the idler gear 77. The counterweights on the arms 82' and continuously urge the roller Li7 upward and into winding contact with the roll throughout the winding operation, and as both arms 82 and S3 are keyed to the tube 84: both swing in unison and maintain a constant and evenly distributed pressure on the roll.. T he frame is appropriately slotted to permit the passage of shaft 8l at all stages of the winding.

l shall now describe the means forv giving the core its longitudinal traverse duri the winding operation, also with particular refer'- ence to Figures l, 2 and 3. The core 26 is he during the winding operation, between two spindles 36 and 87 each provided with rotatable conical centers 88 which enter the ends of the core. The spindle 86 is mounted of the core and the removal of the wound' roll.. Thisv spindle is, however, always urged into core contacting position by means of a spring 91 positioned between the arm 90'and a collar 92 fixed to the spindle. As in the case of the shaft 8l, the frameis slotted to per? mit the swinging of spindles 86 and 87. The core is thusmounted so that it can swing outward during the winding operation and also be moved longitudinally.

The longitudinal traverse of the core is effected as follows The pulley shaft 61 extending beyond the bevel gear 62 is provided with a worm 93 which drives a worm wheel 9a to which is affixed a cam drum 95. Carried at the lower end of swinging arm 89 is a caml roller 96 constantly urged into Contact with the face of the cam drum by means. of a spring 97 interposed between the frame of the machine and a collar 98 fixed to the tube 84, which tube is, as explained before, permitted a limited longitudinal sliding movement. T he configuration of the face of the cam drum 95 is such that during the wind-ing of each roll the core is movedlongitudinally away from the fold of the winding web thus producing-the setback construction illustrated in Figures 9 and 10.

As demonstrated earlier in this specification, the difference between the length of the inner and outer plies for each convolution is 6.28 times the thickness of the web plus the distance between the two plies, which is a constant for any given winding and independent of the diameter of the roll at any convolution. However, as the diameter of the roll increases the actual length of web per convolution increases so that the difference in length in terms of web length decreases. Thus less stretch is required per unit length as the diameter of the roll increases and where large rolls are being wound this should be taken into account; for small rolls the decrease is too small to be of any practical consequence. ln order to decrease the elongation ratio as the winding proceeds I have provided the means illustrated in Figure l5. Here the bar i9 on the folding former, which effects the stretching of half the web, is mounted upon a block 99, urged into contact with a wedge 100 by means of springs 101. The wee ge 100 is mounted upon a threaded shaft 102 rotated by means of handwheel 103, and the position of the bar i9 adjusted accordingly. At the heginning'of each winding operation the handwheel 103 is turned to adlO-S *va-nce the bar 49 to a position for effecting the ation in the position of bar 49 would be automatically controlled. f

Another means for varying the relative lengths of the inner and outer plies is illustrated in Figure 16. The rollers 40 and 41 are replaced by longitudinally corrugated rollers 40 and 41 so that the web is crimped transversely as it passes between them. A. crimped web can be elongated slightly, even when under winding tension, without deformation of the fibers thus when a crimped web is folded and wound the outer ply automatically elongates just sufficient to'compensate for its greater length of travel, and wrinlrling is avoided. The relation of the two plies is illustrated in Figure 17 from which it will be observed that the outer ply has been iattened slightly more than the inner. No special stretching mechanism is required and the relative elongation automatically decreases with increase in the diameter of the roll.l Despite the fact that the two plies of a doublewound crimped roll are of slightly different lengths and that a Vresidual crimp remains, a relatively tight roll can be wound by this method.

The product of my inventionis a tightly wound folded strip free from creases and wrinkles and of uniform diameter. The outer stretched ply may be longer than the inner so that if the entire strip were unwound and unfolded it would curve slightly toward the inner ply. However, when relatively short sections are torn from lthe roll this diiference in length is imperceptible. My invention is particularly useful in connection with winding wrapping paper, especially the tissue used for wrapping gifts. A wide full sheet vmaybe unwound from a short, easily handled roll.

I claim: 1. The method of winding a multi-ply web .which comprises making the outer plies longer than the inner to compensate for the greater length of travel of the outer plies in winding. v.

2. The method of winding a folded web which comprises stretching the outer ply prior to winding to compensate for the greater length of travel of the outer ply in winding.

3. The method of winding a folded web which comprises dampening and stretching the outer ply prior to winding to compensate for the greater length of travel. of the outer ply in winding.

4. The method of winding a folded web which comprises elongating the outer ply to compensate for the greater length of travel of the outer ply in winding, and decreasing the elongation ratio as the winding roll increases in diameter.

5. The method of winding a folded web to form a'roll which comprises winding successive convolutions upon each other while axially displacing them to avoid increasing the diameter of the roll at the fold beyond that of the body of the roll.

6. The method of winding a folded web upon a core to form a roll which comprises winding successive convolutions of the web upon each other while subjecting the core to a longitudinal traverse as the winding proceeds to prevent successive convolutions of the. fold from winding upon each other.

7. The method of winding a web which 'comprises folding the web to form two plies and elongating the outer ply to compensate for the greater length of travel of the outer plies in winding.

f8. The method .of winding a web which comprises continuously drawing the web over folding means, simultaneously stretchving one half of the web and then winding the folded web with the elongated half outermost.

9. The method of winding a web of paper to'form a roll which comprises unwinding the web from a parent roll, dampening one half of the web,.drawing the web over folding means and simultaneously stretching the dampened half, and then winding the folded web upon a core with the elongated half outermost.

10. The method of winding a web of paper to form a roll which comprises unwindingl the web from a parent roll under tension, dampening one half of the web, drawing the web overfolding means and simultaneously stretching the dampened half', winding the folded web upon a core with the elongated half outermost and decreasing the elongation ratio as the roll increases in diameter.

11. The method of winding a folded web which Y comprises stretching the outer ply prior to windingv to compensate for ythe greater length of travel of the outer ply in winding, and axially displacing successive convolutions during winding to avoid increasing the diameter of the roll at the fold beyond that of the body of the roll.

12. The method of winding a web of paper to form a roll which comprises unwinding the web from a parent roll under tension, dampening one half of the web, drawing the web over folding means and simultaneously stretching the dampened half, and then winding the folded web upon a core with the elongated half outermost while subjecting the core to a longitudinal traverse as the winding proceeds to prevent successive convolutions of the fold from winding upon each other.

13. In a web winding machine the combinat-ion of means for winding a multi-p157 web and means for making the outer plies longer than the inner, prior to winding to compensate for the greater length of travel of the outer plies in winding.

14:. In a web winding machine the combination of means for holding a web, means for winding the folded web, and means for stretching the outer ply prior to Winding to compensate for the greater length of travel of the outer plies in Winding.

15. In a web winding machine the combination of means for folding a web, means for winding the folded web, means for dampening the outer ply before winding, and means for stretching the dampened outer ply before winding.

16. In a web winding machine the combination of means for winding a folded web, means for stretching the outer ply as the web approaches the winding means to compensate for the greater length to travel of the outer ply in winding, and means for decreasing the elongation ratio as the Winding roll increases in diameter.

17. In a web Winding machine the combination of means for winding successive convolutions of a folded web upon each other and means for subjecting the winding roll to a longitudinal traverse as the winding proceeds to prevent successive convolutions of the fold from winding upon each other.

18. In a web Winding machine, the combination of means for rotatably supporting a parent roll, a folding former, means for unwinding the web from the parent roll and drawing it over the former to fold it, means for stretching one part of the web as it is folded and means for winding the folded web upon a core.

19. In a web winding machine, the combination of means for rotatably supporting a parent roll, a folding former, means for un- Winding the web from the parent rolland drawing it over the former to fold it, means for dampening one half the web, means for winding the folded web upon a core, and means for stretching the dampened half of the web before winding.

20. In a web winding machine, the combination of means for rotatably supporting a parent roll under tension, a olding former, means for unvvinding the Web from the parent roll drawing it over the former to fold it, means for elevating one edge of the former to increase the path of travel of one half of the web whereby that half is elongated, and means for winding the folded web upon a vcore with the elongated ply outermost.

21. In a web winding machine, the combination of means for rotatably supporting a parent roll under tension, a` folding former, means for unwinding the web from the parent roll drawing it over the former to fold it, means for elevating one edge of the former to increase the path of travel of one half of the web whereby that half is elongated, means for winding the folded web upon a core with the elongated ply outermost, and means for subjecting the core to a longitudinal traverse as the winding proceeds to prevent successive convolutions of the fold from winding upon each other.

22. The method of winding a folded web which comprises crimping it transversely before winding whereby a differential elongation of the two plies is automatically effected during winding.

23. The method of winding a web which comprises crimping the web transversely, folding the web and winding the crimped and folded web.

d24. In a web winding machine the combination of means for rotatably supporting a parent roll, a pair of crimping feed rollers, a folding former, means for unwinding the Web from the parent roll, passing it between the crimping rollers and over the folding former, and means for winding the folded web upon a core.

25. The method of winding a web to form a roll, which comprises folding the web to form two plies, elongating one ply and Winding successive convolutions of the folded web upon each other with the elongated ply outermost while subjecting the winding roll to a longitudinal traverse to prevent successive convolutions of the fold from winding upon each other.

26. In a web winding machine, the combination of means for rotatably supporting a parent roll, a folding former, means for unwinding the Web from the parent roll and drawing it over the former to fold it, means for stretching one part of the web as it is folded, means for winding the folded web upon a core with the stretched ply outermost and means for subjecting the core to a longitudinal traverse as the winding proceeds to prevent successive convolutions of the fold from winding upon each other.

27. In a web winding machine, the combination of means for folding a Web, means for winding the folded web upon a core, spindles for rotatably supporting the core, and a cam for shifting the spindles axially during winding to prevent successive convolutions of the fold from Winding upon each other.

In testimony whereof I affix my signature.

NICHOLAS MARCALUS.

CERTIFICATE OF CORRECTION.

Patent No. 1,884,783. October-275, 1932.

NICHOLAS MARCALUS.

lt is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 5, line 6, claim 14, for "holding read "folding"; and line 21, claim 16, for "to" read "of"; and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 29th day of November, A. D. 1932.

M. Jl Moore, (Seal) Acting Commissioner of Patents. 

